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NASA NTRS2012

Best Practices from the Design and Development of the Ares I Launch Vehicle Roll and Reaction Control Systems

On April 15, 2010 President Barak Obama made the official announcement that the Constellation Program, which included the Ares I launch vehicle, would be canceled. NASA s Ares I launch vehicle was being designed to launch the Orion Crew Exploration Vehicle, returning humans to the moon, Mars, and beyond. It consisted of a First Stage (FS) five segment solid rocket booster and a liquid J-2X Upper Stage (US) engine. Roll control for the FS was planned to be handled by a dedicated Roll Control System (RoCS), located on the connecting interstage. Induced yaw or pitch moments experienced during FS ascent would have been handled by vectoring of the booster nozzle. After FS booster separation, the US Reaction Control System (ReCS) would have provided the US Element with three degrees of freedom control as needed. The best practices documented in this paper will be focused on the technical designs and producibility of both systems along with the partnership between NASA and Boeing, who was on contract to build the Ares I US Element, which included the FS RoCS and US ReCS. In regards to partnership, focus will be placed on integration along with technical work accomplished by Boeing. This will include detailed emphasis on task orders developed between NASA and Boeing that were used to direct specific work that needed to be accomplished. In summary, this paper attempts to capture key best practices that should be helpful in the development of future launch vehicle and spacecraft RCS designs.

Butt, Adam↗

NASA NTRS2012

Manufacturing of 5.5 Meter Diameter Cryogenic Fuel Tank Domes for the NASA Ares I Rocket

The Ares I rocket is the first launch vehicle scheduled for manufacture under the National Aeronautic and Space Administration s (NASA s) Constellation program. A series of full-scale Ares I development articles have been constructed on the Robotic Weld Tool at the NASA George C. Marshall Space Flight Center in Huntsville, Alabama. The Robotic Weld Tool is a 100 ton, 7-axis, robotic manufacturing system capable of machining and friction stir welding large-scale space hardware. This presentation will focus on the friction stir welding of 5.5m diameter cryogenic fuel tank components; specifically, the liquid hydrogen forward dome (LH2 MDA) and the common bulkhead manufacturing development articles (CBMDA). The LH2 MDA was the first full-scale, flight-like Ares I hardware produced under the Constellation Program. It is a 5.5m diameter elliptical dome assembly consisting of eight gore panels, a y-ring stiffener and a manhole fitting. All components are made from aluminum-lithium alloy 2195. Conventional and self-reacting friction stir welding was used on this article. Manufacturing solutions will be discussed including the implementation of photogrammetry, an advanced metrology technique, as well as fixtureless welding. The LH2 MDA is the first known fully friction stir welded dome ever produced. The completion of four Common Bulkhead Manufacturing Development Articles (CBMDA) will also be highlighted. Each CBMDA consists of a 5.5m diameter spun-formed dome friction stir welded to a y-ring stiffener. The domes and y-rings are made of aluminum 2014 and 2219 respectively. An overview of CBMDA manufacturing processes and the effect of tooling on weld defect formation will be discussed.

Jones, Ronald E.↗

NASA NTRS2014

ARES Education and Public Outreach

The ARES Directorate education team is charged with translating the work of ARES scientists into content that can be used in formal and informal K-12 education settings and assisting with public outreach. This is accomplished through local efforts and national partnerships. Local efforts include partnerships with universities, school districts, museums, and the Lunar and Planetary Institute (LPI) to share the content and excitement of space science research. Sharing astromaterials and exploration science with the public is an essential part of the Directorate's work. As a small enclave of physical scientists at a NASA Center that otherwise emphasizes human space operations and engineering, the ARES staff is frequently called upon by the JSC Public Affairs and Education offices to provide presentations and interviews. Scientists and staff actively volunteer with the JSC Speaker's Bureau, Digital Learning Network, and National Engineers Week programs as well as at Space Center Houston activities and events. The education team also participates in many JSC educator and student workshops, including the Pre-Service Teacher Institute and the Texas Aerospace Scholars program, with workshop presentations, speakers, and printed materials.

Allen, Jaclyn↗

NASA NTRSDate not supplied

Developmental Flight Instrumentation: Review of Space Shuttle, Ares I-X, and Artemis I

Ascent vehicles in the developmental stages of the program are instrumented with Developmental Flight Instrumentation (DFI) sensors. These sensors establish a link between a vehicle and engineers on the ground to communicate conditions experienced during the ascent. These data are then compared to pre-flight predictions used in the design process. The aerodynamic, acoustic, thermal, and structural data are either telemetered to ground stations during the ascent or stored on the vehicle for post-flight recovery and archived at the Huntsville Operations Support Center (HOSC). Following NASA's Artemis I Space Launch System (SLS) launch on November 16, 2020, data from three separate programs are available at the HOSC: Space Shuttle Program (Space Transport System (STS)), Constellation Program (Ares I-X), and Artemis Program (SLS). Availability of these data presents a unique opportunity to examine DFI data from three distinct vehicles and analyze the broad impact of the DFI data on the understanding of transonic aerodynamics. Classical spectrogram and Empirical Mode Decomposition techniques were used to present data in aerodynamically analogous regions on each vehicle. On the SLS and Ares I-X, a region downstream of the Launch Abort System motors was chosen. Comparing SLS and the STS, a region downstream of booster Froward Attach Hardware was selected as analogous flow region. Some other regions of interest were also identified. Although similarities in flow features on three vehicles were identified, some challenges in the comparison were also encountered, especially due to poor temporal and spatial resolution of Shuttle measurements.

Space Shuttle↗

NASA NTRSDate not supplied

Developmental Flight Instrumentation: Review of Space Shuttle, Ares I-X, and Artemis I

Space Shuttle↗

NASA NTRS1992

Developing a control system for ARES 2

A great deal of analysis and testing is conducted at the NASA Langley Research Center to support the development of safe and reliable helicopter rotor systems. This work is performed by the Rotorcraft Aeroelasticity Group located in the Transonic Dynamics Tunnel (TDT) facility. Over the past two decades a wide variety of tests have been successfully conducted in the TDT and their results have contributed significantly to the understanding of aeromechanical phenomena in rotor systems. This has led to improved tools for analysis and design, and ultimately to the development, of improved rotor systems. The TDT facility is ideally suited for these tests due to its unique ability to use a heavy gas as a working medium. This allows the model to be scaled such that the results obtained may be readily extrapolated to full scale. Until recently, the rotor system to be tested has been mounted on a fixed balance which is attached to the longeron which is attached to the stand through a single pitching degree of freedom. The testbed used is known as the Aeroelastic Rotor Experimental System (ARES 1). In order to extend the experimental capabilities to investigate the full rotor/body dynamic coupling present in a rotorcraft, a very ambitious project has been undertaken to design and construct a six degree of freedom system that can be controlled so as to emulate the inertial characteristics of a prescribed model fuselage. The electronic and mechanical hardware for this system has already been designed and constructed. This system is known ar ARES II. The rotor and its drive system are mounted on the balance which is attached to the longeron via six hydraulic actuators. This six degree of freedom parallel linkage is referred to in the literature as a Stuart Platform. By properly adjusting the length of the hydraulic actuators it is possible to position and orient the balance relative to the longeron. The longeron is attached to the stand via a pitch degree of freedom to allow testing over various forward flight regimes. One major task remaining to complete this testbed is the design and synthesis of a control system. To do this properly requires an understanding of the kinematics and dynamics of the system and robust control design. A brief description of the development of a control design is given.

Fitzsimons, Philip M.↗

NASA NTRS1999

Sampling the Old and the New: Landing Site Proposals for the Dichotomy Boundary (6 S,210 W) and the Ares Vallis Headlands (2 S,18 W)

One of the goals of the Mars Pathfinder mission was to sample a diversity of rocks deposited by the Ares and Tiu Vallis floods. It was hoped that ancient highlands and younger lowlands material could be studied, as well as a diversity of rocks within these regions. Although Pathfinder found rocks that exhibited a number of textures and morphologies, several factors precluded the identification of a petrologic suite of rocks, if it was present. Namely among these were 1) The lack of geologic context for the rocks examined, 2) instrument limitations, and 3) pervasive dust and possible weathering finds. Based on the Pathfinder experience and incorporating recent results from Mars Global Surveyor and previous missions, two landing sites are proposed that can potentially overcome this problem and offer samples of ancient and recent Martian rock. The first site is at the dichotomy boundary, where ancient highlands and more recent lowlands meet. The second site is at the Ares Vallis headlands, where some of the source materials for the Pathfinder landing site may have been derived. Both of these sites meet the remote sensing and elevation constraints of the 2001 Lander mission but exhibit significant slopes and potential hazards in places. However, a properly placed ellipse can alleviate much of the concern, thereby offering two exciting sites that otherwise would not be chosen.

Bridges, N. T.↗

NASA NTRS2003

Preliminary Design and Analysis of the ARES Atmospheric Flight Vehicle Thermal Control System

The Aerial Regional-scale Environmental Survey (ARES) is a proposed 2007 Mars Scout Mission that will be the first mission to deploy an atmospheric flight vehicle (AFV) on another planet. This paper will describe the preliminary design and analysis of the AFV thermal control system for its flight through the Martian atmosphere and also present other analyses broadening the scope of that design to include other phases of the ARES mission. Initial analyses are discussed and results of trade studies are presented which detail the design process for AFV thermal control. Finally, results of the most recent AFV thermal analysis are shown and the plans for future work are discussed.

Gasbarre, J. F.↗

NASA NTRS2004

Liquid Rocket Propulsion for Atmospheric Flight in the Proposed ARES Mars Scout Mission

Flying above the Mars Southern Highlands, an airplane will traverse over the terrain of Mars while conducting unique science measurements of the atmosphere, surface, and interior. This paper describes an overview of the ARES (Aerial Regional-scale Environmental Survey) mission with an emphasis on airplane propulsion needs. The process for selecting a propulsion system for the ARES airplane is also included. Details of the propulsion system, including system schematics, hardware and performance are provided. The airplane has a 6.25 m wingspan with a total mass of 149 kg and is propelled by a bi-propellant liquid rocket system capable of carrying roughly 48 kg of MMH/MON3 propellant.

Kuhl, Christopher A.↗

NASA NTRS2005

Advanced Resistive Exercise Device (ARED) Flight Software (FSW): A Unique Approach to Exercise in Long Duration Habitats

ARED flight instrumentation software is associated with an overall custom designed resistive exercise system that will be deployed on the International Space Station (ISS). This innovative software application fuses together many diverse and new technologies into a robust and usable package. The software takes advantage of touchscreen user interface technology by providing a graphical user interface on a Windows based tablet PC, meeting a design constraint of keyboard-less interaction with flight crewmembers. The software interacts with modified commercial data acquisition (DAQ) hardware to acquire multiple channels of sensor measurment from the ARED device. This information is recorded on the tablet PC and made available, via International Space Station (ISS) Wireless LAN (WLAN) and telemetry subsystems, to ground based mission medics and trainers for analysis. The software includes a feature to accept electronically encoded prescriptions of exercises that guide crewmembers through a customized regimen of resistive weight training, based on personal analysis. These electronically encoded prescriptions are provided to the crew via ISS WLAN and telemetry subsystems. All personal data is securely associated with an individual crew member, based on a PIN ID mechanism.

Mangieri, Mark↗

NASA NTRS2007

NDE Development for Inspection of the Ares I Crew Launch Vehicle

NASA is designing a new crewed launch vehicle called Ares I to replace the Space Shuttle after its scheduled retirement in 2010. This new launch vehicle will build on the Shuttle technology in many ways including using a first stage based upon the Space Shuttle Solid Rocket Booster, advanced aluminum alloys for the second stage tanks, and friction stir welding to assemble the second stage. Friction stir welding uses a spinning pin that is inserted in the joint between two panels that are to be welded. The pin mechanically mixes the metal together below the melting temperature to form the weld. Friction stir welding allows high strength joints in metals that would otherwise lose much of their strength as they are melted during the fusion welding process. One significant change from the Space Shuttle that impacts NDE is the implementation of self-reacting friction stir welding for non-linear welds on the primary metallic structure. The self-reacting technique differs from the conventional technique because the load of the pin tool pressing down on the metal being joined is reacted by a nut on the end of the tool rather than an anvil behind the part. No spacecraft has ever flown with a self-reacting friction stir weld, so this is a major advancement in the manufacturing process, bringing with it a whole new set of challenges for NDE to overcome. Another impact is the proposed usage of an aluminum face sheet, phenolic honeycomb sandwich structure for a common bulkhead between the fuel and oxidizer tanks. This design was used on the second stage of Saturn IB and the second and third stages of Saturn V, but both the manufacturing and subsequent inspection were very costly and time consuming so a more efficient inspection method is sought. The current state of development of these inspections will be presented, along with other information pertinent to NDE of the Ares I.

Richter, Joel↗

NASA NTRS2006

GNC Architecture Design for ARES Simulation. Revision 3.0

The purpose of this document is to describe the GNC architecture and associated interfaces for all ARES simulations. Establishing a common architecture facilitates development across the ARES simulations and provides an efficient mechanism for creating an end-to-end simulation capability. In general, the GNC architecture is the frame work in which all GNC development takes place, including sensor and effector models. All GNC software applications have a standard location within the architecture making integration easier and, thus more efficient.

Gay, Robert↗

NASA NTRS2007

Building Operations Efficiencies into NASA's Ares I Crew Launch Vehicle Design

The U.S. Vision for Space Exploration guides the National Aeronautics and Space Administration's (NASA's) challenging missions that expand humanity's boundaries and open new routes to the space frontier. With the Agency's commitment to complete the International Space Station (ISS) and to retire the venerable Space Shuttle by 2010, the NASA Administrator commissioned the Exploration Systems Architecture Study (ESAS) in 2005 to analyze options for safe, simple, cost-efficient launch solutions that could deliver human-rated space transportation capabilities in a timely manner within fixed budget guidelines. The Exploration Launch Projects (ELP) Office, chartered by the Constellation Program in October 2005, has been conducting systems engineering studies and business planning to successively refine the design configurations and better align vehicle concepts with customer and stakeholder requirements, such as significantly reduced life-cycle costs. As the Agency begins the process of replacing the Shuttle with a new generation of spacecraft destined for missions beyond low-Earth orbit to the Moon and Mars, NASA is designing the follow-on crew and cargo launch systems for maximum operational efficiencies. To sustain the long-term exploration of space, it is imperative to reduce the $4 billion NASA typically spends on space transportation each year. This paper gives toplevel information about how the follow-on Ares I Crew Launch Vehicle (CLV) is being designed for improved safety and reliability, coupled with reduced operations costs. These methods include carefully developing operational requirements; conducting operability design and analysis; using the latest information technology tools to design and simulate the vehicle; and developing a learning culture across the workforce to ensure a smooth transition between Space Shuttle operations and Ares vehicle development.

Dumbacher, Daniel L.↗

NASA NTRS2007

TFAWS: Ares Thermal Overview

As part of a Constellation session at the 2007 Thermal & Fluids Analysis Workshop (TFAWS), an overview of the Crew Launch Vehicle (CLV), Crew Exploration Vehicle (CEV) and Lunar Lander systems will be given. This presentation provides a general description of the CLV (also known as Ares-I)and Ares-V vehicles portion of the session. The presentation will provide an overview of the thermal requirements, design environments, challenges and thermal modeling examples.

Sharp, John R.↗

NASA NTRS2007

Ablation Modeling of Ares-I Upper State Thermal Protection System Using Thermal Desktop

The thermal protection system (TPS) for the Ares-I Upper Stage will be based on Space Transportation System External Tank (ET) and Solid Rocket Booster (SRB) heritage materials. These TPS materials were qualified via hot gas testing that simulated ascent and re-entry aerothermodynamic convective heating environments. From this data, the recession rates due to ablation were characterized and used in thermal modeling for sizing the thickness required to maintain structural substrate temperatures. At Marshall Space Flight Center (MSFC), the in-house code ABL is currently used to predict TPS ablation and substrate temperatures as a FORTRAN application integrated within SINDA/G. This paper describes a comparison of the new ablation utility in Thermal Desktop and SINDA/FLUINT with the heritage ABL code and empirical test data which serves as the validation of the Thermal Desktop software for use on the design of the Ares-I Upper Stage project.

Sharp, John R.↗

NASA NTRS2007

Ares Projects Office Progress Update

NASA's Vision for Exploration requires a safe, reliable, affordable launch infrastructure capable of replacing the Space Shuttle for low Earth orbit transportation, as well as supporting the goal of returning humans to the moon. This presentation provides an overview of NASA's Constellation program and the Ares I and Ares V launch vehicles, including accomplishments and future work.

Vanhooser, Teresa↗

NASA NTRS2008

Gas Strut Separation Alternative for Ares I

This paper presents a design alternative and the rationale for a stage separation system based on Metering Adiabatic Gas Struts (MAG Struts) for the Ares 1 launch vehicle. The MAG Strut separation system was proposed as an alternative to the current Ares 1 separation system, which relies on small solid rocket motors to provide the main separation force. This paper will describe technical issues that were addressed during the trade study and present a conceptual design of the strut system that best resolved the issues. Needed development testing and programmatic considerations will be addressed as part of the paper.

Floyd, Brian↗

NASA NTRS2008

Ares Integrated Vehicle System Safety Team

NASA is working on the Constellation Program to go to the Moon and beyond. The Program contains a number of projects: a) The Ares I Launch Vehicle for the Orion Crew Module; b) The Ares V Launch Vehicle to launch large payloads into orbit, including the Earth Departure Stage (EDS); d) The Orion vehicle to transport the crew to orbit and to other destinations; and d - The Altair Lunar Lander

Wetherholt, Jon↗